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Major Projects Completed

Seam tracking system for Weld Automation

Welding Research Institute (WRI) has developed seam-tracking systems which can be effectively employed for welding automation. Two different types of weld seam trackers have been developed at WRI. The first type of seam tracker is based on non-contact inductive type position sensor and the second type is based on through-the arc sensing. Ministry of Information Technology (MIT) has sponsored this development.

The inductive sensor based seam tracker can be applied for fillet welds in large beams, circular fillets of flanges etc. Through the arc sensing based seam tracker can be employed with oscillating torch GMAW as the process for butt welded joints The major benefits of employing seam trackers are Improved quality and increased productivity of welded joints by avoiding defects due to mis-alignment of seams. Precise control over the job conditions during welding and less dependency on the operator are additional benefits. 


Versatile All Position In-situ metallographic polishing Equipment (VAPINE)

Over the years a number of special purpose in-situ polishing devices such as Controlled Electro Polisher In-situ (CEPIN), All Position In-situ Electro polisher (APINE) and Versatile All position In-situ Electro polisher (VAPINE) have been developed to enable metallographic polishing in difficult location. With these techniques it is also possible to carry out high quality replication even on warm components.


Narrow Gap Submerged Arc Welding Technology

Conventional arc welding techniques make use of wider weld grooves with included angles of 60-90 for plate thickness upto 50 mm in general. For higher thickness, the edge preparation comprises of a relatively wider root preparation with 10 to 20 included angle. The edge preparations call for considerable deposition of weld metal and consumption of flux. Modern fabrication techniques aim at maximising productivity and cost savings. Narrow Gap Welding Technique applied to conventional arc welding processes is a potential tool for welding fabrication industry for achieving this goal especially for welding of thick section joints using submerged arc welding. WRI has developed modular type narrow gap welding head, which can be interfaced with conventional Submerged Arc Welding system having suitable rigidity. Narrow Gap technology has been established for butt welding steel plates upto 180 mm thickness.

Applications of high energy density Electron Beam Welding Technology

Electron Beam Welding (EBW) facility available at WRI was retrofitted with CNC controlled positioning tables and control systems. With this facility, welding of stainless steel, aluminium and copper alloys have been successfully established and applied to industrial products.


Jobbing & Repair services
WRI has carried out number of repair jobs for critical applications involving various types of cast iron, alloy steels and non-ferrous alloys. These include
Severely damaged hydro turbine runners weighing 13 tonnes made of martensitic stainless steel.
Extensively cracked Nickel valve casting of chemical plants.
Circumferentially cracked Carbon Manganese hydraulic steel cylinders of paper mill.
As a part of the continuing community service, temple bells of Brahadeeswar temple, Thanjavur and Swaminathaswamy temple, Swamimalai were repaired and handed over to the
temple authorities.
Worn out forged dies, steel roll mills, bowl mill coal crusher rolls and crane wheels.
Severely cracked ancient church and temple bells made of bronze.
Fabrication of components for Aluminium bridges, foundation bolts, damper flappers, MgO filled thin sheet thermocouples
Surfacing of pulverising rolls, valve wedges, seat rings


Development of Electrodes & Fluxes
Following stick electrodes and Submerged Arc Welding fluxes have been developed.
General purpose all position welding electrodes conforming to AWS E 6012, E 6013, E 7018.
Low Alloy Steel Electrode conforming to E7018A1, E8018 B2 & E9018 B3.
Austenitic stainless steel electrode conforming to AWS E308 with controlled ferrite, E410 & E430.
Special purpose hardfacing electrode for sugar cane crusher rolls and worn out components of cement industry.
Fused flux for high speed and Narrow Gap welding techniques.


Development of Welding Procedure

Extensive weldability evaluation of indigenously developed high strength low alloy steel and quenched & tempered steels for structural and pressure vessel applications have been done. The susceptibility of the materials for hot cracking, hydrogen induced cold cracking and lamellar tearing was thoroughly examined using different types of weldability tests. Welding parameters have been optimized and safe welding procedures have been recommended. Welding procedures have also been established for a variety of industrial components such as heat exchangers, pressure vessels, pen stocks, steam turbines and number of critical applications to enable arriving at appropriate Welding Procedure Specifications.

Remaining Life Assessment of Power and Process plants

Remaining Life and Condition Assessment studies of several Power, Chemical, Process and Fertilizer plants have been conducted through elaborate Non Destructive Examination and In-situ metallography

The extent, nature and type of damage have been thoroughly analysed and recommendations on appropriate Run-Retire-Repair and periodicity of inspection have been made.


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